LED sign cover and method of manufacture

Abstract

A cover for a LED sign is manufactured from a stainless steel sheet that is dimensionally larger than the array of light emitting diodes comprising the LED sign. The stainless steel sheet is laser cut and then bent to simultaneously form a plurality of apertures and a corresponding plurality of louvers each extending adjacent one of the apertures. The apertures facilitate viewing of the LED sign and the louvers shield the light emitting diodes comprising the LED sign from excessive light.

1. A LED sign for urban transit vehicles comprising
 a substantially vertical array of light emitting diodes; 
 a cover overlying the entirety of the substantially vertical array of light emitting diodes, the cover comprising a substantially flat sheet formed from stainless steel which defines a predetermined plane; 
 a plurality of louvers for shielding the light emitting diodes from excessive light, each of the louvers comprising a portion of the stainless steel sheet that is integrally connected to the stainless steel sheet, the louvers having a first position wherein the louvers are positioned in a same plane as the plane of the cover and a second position wherein the louvers are bent into a predetermined angle relative to the plane of the cover, wherein once the louvers are moved from the first position to the second position they remain in the second position; and 
 wherein the cover further defines a plurality of apertures to facilitate viewing of the light emitting diodes therethrough when the plurality of louvers are in the second position, each of the plurality of louvers located within a corresponding aperture when the plurality of louvers are within the first position before moving to the second position, each of the plurality of apertures defined by a space remaining in the cover when a corresponding louver moves from the first position to the second position. 
 
   
   
     2. The improvement according to  claim 1  wherein substantially all of the apertures formed in the cover are substantially identical in size and shape and wherein substantially all of the apertures formed in the cover extend substantially parallel to one another. 
   
   
     3. The improvement according to  claim 2  wherein the light emitting diodes comprising the LED signs are arranged in a rectangular array comprising the first relatively long dimension and a second relatively short dimension extending perpendicularly to the first relatively long dimension; and
 wherein the apertures formed in the cover extend substantially parallel to the first relatively long dimension characterizing the array of light emitting diodes. 
 
   
   
     4. A method of manufacturing a cover for a LED sign comprising an array of light emitting diodes characterized by predetermined dimensions including the steps of:
 providing a sheet of opaque material which is dimensionally larger than the array of light emitting diodes comprising the LED sign; 
 forming at least one aperture in the sheet of opaque material to facilitate viewing of the light emitting diodes comprising the LED sign; 
 the aperture forming step including the step of forming a cut in the sheet of opaque material which comprises a first relatively long cut line and two relatively short second cut lines each extending angularly relative to the first cut line from the opposite ends thereof and 
 bending the portion of the sheet of opaque material extending between the two second cut lines thereby simultaneously forming the aperture in the sheet of opaque material and a louver substantially equal in size to the aperture and positioned adjacent to the aperture which shields the array of light emitting diodes from excessive light and enables viewing of the light emitting diodes from a position perpendicular to a plane of the sheet of opaque material. 
 
   
   
     5. The method of according to  claim 4  wherein the step of providing a sheet of opaque material is carried out by providing a stainless steel sheet. 
   
   
     6. The method of according to  claim 5  wherein the step of forming the first and second cut lines is carried out by laser cutting the stainless steel sheet. 
   
   
     7. The method according to  claim 6  wherein the step of forming first and second cut lines is carried out by forming second cut lines at the opposite ends of the first cut line which extend perpendicularly relative to the first cut line. 
   
   
     8. The method according to  claim 7  wherein the cutting and bending steps are replicated thereby forming a plurality of apertures of the stainless steel sheet and a plurality of louvers each positioned adjacent one of the apertures. 
   
   
     9. A method of manufacturing a cover for a LED sign comprising an array of light emitting diodes characterized by predetermined dimensions including the steps of:
 providing a stainless steel sheet which is dimensionally larger than the array of light emitting diodes comprising the LED sign; 
 forming a plurality of apertures in the stainless steel sheet to facilitate viewing of the light emitting diodes comprising the LED sign; 
 the aperture forming step including the steps of forming cuts in the stainless steel sheet each comprising a relatively long first cut line and two relatively short second cut lines each extending angularly relative to the first cut line from the opposite ends thereof; and 
 bending the portions of the stainless steel sheet extending between the two second cut lines thereby simultaneously forming the apertures in the stainless steel sheet and louvers substantially equal in size to the apertures and positioned adjacent to the apertures which shield the array of light emitting diodes from excessive light and enables viewing of the light emitting diodes from a position perpendicular to a plane of the stainless steel sheet. 
 
   
   
     10. The method according to  claim 9  wherein the steps of forming the first and second cut lines is carried out by laser cutting the stainless steel sheet. 
   
   
     11. The method according to  claim 10  wherein the step of forming first and second cut lines is carried out by forming second cut lines at the opposite ends of the first cut lines which extend perpendicularly relative to the first cut lines. 
   
   
     12. The method according to  claim 11  wherein the step of forming apertures in the stainless steel sheet is carried out by forming apertures which are substantially identical in size and shape and further characterized by forming apertures in the stainless steel sheet which extend substantially parallel to one another. 
   
   
     13. The method according to  claim 12  wherein the light emitting diodes comprising the LED sign are arranged in a rectangular array comprising a first relatively long dimension and a second relatively short dimension extending perpendicularly to the first relatively long dimension and wherein the step of forming apertures in the stainless steel sheet is carried out by forming apertures which extend substantially parallel to the first long dimension characterizing the array of light emitting diodes.